Composite wall panel

ABSTRACT

A structural, insulating, insect resistant, dimensionally stable composite wall panel for building construction comprising a regular tetragonal body of polymer foam having two opposing primary wall surfaces bounded on its sides by two parallel side walls and on its ends by two parallel end walls; and at least one light metal gauge hollow stud in the body, each light metal gauge stud extending at least from one end wall to the other end wall and parallel to the side walls of said body, the polymer foam extending into the center of the stud to secure the stud to the body, at least one side wall of each stud forming a portion of the same primary wall surface of said body.

Applicants claim the benefit of prior filed co-pending provisionalpatent application Ser. No. 60/018,050 on COMPOSITE WALL PANEL filed onMay 21, 1996 and co-pending U.S. patent application Ser. No. 08/683,670filed Jul. 17, 1996. This is a continuation-in-part of said applicationSer. No. 08/683,670.

1. Field of the Invention

The present invention is directed to polymer/metal composite wallpanels. In particular, lightweight, thermal and sound insulating,polymer/metal composite wall panels. The panels, optionally, andpreferably, also constitute structural supporting members.

2. Background of the Invention

Composite building panels are known to the art. Dickens U.S. Pat. No.4,953,334 discloses a building panel having an expanded cellular corewith side edge reinforcing strips. The panels fit in a complementarymanner with stepped core edges of different step widths to formrectangular troughs along the edges of mating panels for utility lines.Panels are used for renovation of existing building structures whereinthe panels are applied on the existing building walls.

Gulur U.S. Pat. No. 5,279,089 discloses an insulated wall systemcomprising tubular support members secured to footings and headers. Thespace between the tubular support members are filled with extrudedpolymer foam sheets in a three ply sandwich construction.

The panel of U.S. Pat. No. 4,953,334 is made for applying to an existingwall structure and is not a structural supporting member. Thereinforcement strips are a custom design and cannot be purchased off theshelf.

U.S. Pat. No. 5,279,089 discloses a wall system which is built fromscratch on site in the same manner that wood frame walls areconstructed. Structural supporting panels are not used in U.S. Pat. No.5,279,089 patent and the tubular framing must be accurately centered andsecured to the headers and footers in order that the insulated polymericfoam panels can be inserted into the space between adjacent tubularsupport members with a minimum of cutting and "fitting".

The U.S. Pat. No. 5,279,089 patent discloses that a division of theAtlantic Richfield Company markets a wall system of expanded polystyreneand metal frame members under the trademark WALLFRAME and that NU-TECHBuilding Systems of Cleveland, Ohio markets a wall system of the sametype under the trademark CANOTHERMO.

SUMMARY OF THE INVENTION

One embodiment of the present invention is directed to a structural,insulating, insect resistant, dimensionally stable composite wall panelfor building construction comprising a regular tetragonal body ofpolymer foam having two opposing primary wall surfaces bounded on itssides by two parallel side walls and on its ends by two parallel endwalls; and at least one light metal gauge stud in the body, the studhaving a hollow center cavity, a squared cross section with a wide backwall extending the width of the stud, two parallel side walls, twonarrow front walls parallel to the back wall and separated by an openslot extending into the central cavity, each light metal gauge studextending at least from one end wall to the other end wall of said bodyand parallel to the side walls of said body, the polymer foam extendinginto the central cavity of the stud to secure the stud to the body, andat least one side wall of each stud forming a portion of the sameprimary wall surface of said wall panel.

The opposing primary wall surfaces are the major wall surfaces that willconstitute room walls, exterior walls and the like. The studs employedin the present invention are the light metal gauge studs, which areemployed throughout the United States and may other countries, whichhave a squared or regular tetragonal cross section.

For composite wall panels employed in the interior of a building, thewidth of the panel between the two primary wall surfaces will normallybe equal to the width of the studs and the side wall of the studs willform a portion of both the primary wall surfaces. In other words, theside walls of the studs will be visible as a portion of both primarywall surfaces of the panel prior to finishing off the panel as a wallsurface with plaster, gypsum wall board, wood paneling and the like.

The top and bottom ends of the composite wall panels are adapted to bereceived by and secured in the open channel of light metal gaugebuilding construction tracks to form a structural wall. The compositewall panels have a tongue adapted to be received and fastened in theopen channel of the track. Other composite wall panels have a grooveforming the tongue, other panels have a tongue formed in the panel orcreated by cutting the foam to form the end tongues. The panels aresecured to the tracks by fasteners, such as self-tapping threadedfasteners, which extend through the wall of the track into the side wallof the studs. The bottom track is attached to the floor system of thebuilding and the top track will support the ceiling, upper flooring androofing members of the building.

In a preferred embodiment of the present invention, a stud will be oneof the side walls of the body. Even more preferably, the back wall of astud will be one of the side walls of the body.

In the preferred embodiment of the present invention, the panels widthwill be equal to a standard center to center distance of studs forstandard building construction or an integral multiple thereof. Forexample, 16 inches is a standard building construction stud center tocenter distance employed in the U.S. The panels can be 60 inches wide,32 inches wide, or 48 inches wide, and the like. For some construction,the center to center distance is 12 inches and for other applications,the center to center distance can be 24 inches. For exteriorconstruction, the panel will preferably have at least two light metalgauge studs which are distanced apart from each other center to center astandard building construction center to center distance for studs, suchas 12 inches, 16 inches or 24 inches or a multiple thereof.

When the composite wall panel is wider than the stud width, and a studis positioned on the side wall of said body, the stud will only form apart of the side wall since is it not wide enough to cover the entirewidth of the side wall. For composite wall panels that are wider thanthe studs, the panel can have a tongue portion at each of its ends. Thetongue portion will have a width equal to the width of the studs and thetongues will be adapted to be received by and secured in the openchannel of light metal gauge building construction track to form astructural wall. Alternatively, and preferably, the panel will have agroove at each of its ends. The distance between the groove and one wallof the panel will be at least equal to the width of a stud and willpermit the panel to be dropped into a bottom track with one wall of thetrack mating with the wall of the panel and the other wall of the trackbeing received in the groove at the end of the stud.

A preferred composite panel of the present invention comprises astructural, insulating, insect resistant, dimensionally stable compositewall panel for building construction comprising a regular tetragonalbody of polymer foam having two opposing wall surfaces bounded on itssides by two parallel side walls and on its ends by two parallel endwalls; and one light metal gauge stud in the body, the stud having ahollow center cavity, squared cross section with a wide back wallextending the width of the stud, two parallel side walls, two narrowfront walls separated by an open slot extending into the central cavity,light metal gauge extending at least from one end wall to the other endwall of said body and parallel to the side walls of said body, thepolymer foam extending into the central cavity of the stud to secure thestud to the body, the width of the panel between the two primary wallsurfaces equal to the width of the stud and the side walls of the studforming a portion of the primary wall surfaces; the back wall of thestud is one of the side walls of said body, and the ends of said bodyadapted to be received by and secured in the open channel of light metalgauge building construction track to form a structural wall.

A further preferred embodiment of the present invention comprises astructural, insulating, insect resistant, dimensionally stable compositewall panel for building construction comprising a regular tetragonalbody of polymer foam having two opposing primary wall surfaces boundedon its sides by two parallel side walls and on its ends by two parallelend walls; and at least two light metal gauge studs in the body, eachstud having a hollow center cavity, a squared cross section with a wideback wall extending the width of the stud, two parallel side walls, twonarrow front walls separated by a open slot extending into the centralcavity, each light metal gauge stud extending at least from one end wallto the other end wall of said body and parallel to the side walls ofsaid body. The polymer foam extending into the central cavity of thestuds to secure the studs to the body, the width of the panel betweenthe primary wall surfaces being greater than the width of the studs, atleast one side wall of each stud forming a portion of the same primarywall surface of said body, the back wall of one stud being a part of oneof the side walls of said body, said body having a tongue portion ateach of its ends, the tongue portion having a width equal to the widthof the studs, the tongue portion adapted to be received by and securedin the open channel of light metal gauge building construction track toform a structural wall.

The preferred wall panel system of the present invention a structuralwall for building construction based on a light metal gauge stud, achannel and track construction, comprising a light metal gauge trackwith an open channel secured for building floor system and a secondlight metal gauge track with an open channel for receiving, securing andsupporting a ceiling and roofing structural members, the tracksseparated by, supported by and secured to each other with two or morestructural, insulating, insect resistant, dimensionally stable compositewall panels for building construction, each panel comprising a regulartetragonal body of polymer foam having two opposing primary wallsurfaces bounded on its sides by two parallel side walls and on its endsby two parallel end walls; at least two light metal gauge studs in thebody, each stud having a hollow center cavity, a squared cross sectionwith a wide back wall extending the width of the stud, two parallel sidewalls, two narrow front walls parallel to the back wall and separated byan open slot extending into the central cavity, each light metal gaugestud extending at least from one end wall to the other end wall of saidbody and parallel to the side walls of said body, and polymer foamextending into the central cavity of the stud to secure the stud to thebody, at least one side wall of each stud forming a portion of the sameprimary wall surface of said body, the distance between the studs, fromcenter to center of the studs, is a standard building constructioncenter to center distance for studs, studs of the panels being securedto the first and second tracks by self-threaded screws extending throughthe side walls of the tracks into the side walls of the studs.

The present invention is directed to a lightweight, thermal and soundinsulating, polymer/metal composite wall panel. The wall panel ispreferably a structural supporting member for the construction of abuilding. The panels can be utilized on the exterior walls and in theinterior walls of the building. The invention is also directed to a wallsystem comprised of a plurality of assembled lightweight, thermal andsound insulating, polymer/metal composite wall panels as describedherein.

The lightweight, thermal and sound insulating polymer/metal compositewall panels (hereinafter referred to as "composite wall panels")comprise a continuous panel of extruded or expanded closed cell, polymerfoam having flat parallel exterior surface and interior surface,parallel longitudinal sides, parallel end sides and at least one lightmetal gauge stud embedded in the polymer foam panel with one side ofeach stud exposed on the interior side of the wall panel and extendingthe full longitudinal length of the wall panel. The wall panel isadapted to be received and fastened in a light gauge metal bottom trackand top track for the construction of exterior and interior walls of abuilding.

The light gauge metal studs are positioned in the wall panel at equaldistances so that when wall panels are assembled together they to form awall system of two or more wall panels with the metal studs positionedequal distance from each other on centers, such as 12 inches, 16 inches,24 inches and 48 inches centers.

In another embodiment of the present invention, the metal studs arerectangular in cross section having an open slot running the length ofthe stud. The studs optionally have one or more holes in their backwall. The central cavity of each stud is filled with the polymeric foamof the wall panel. One of the studs is preferably positioned to formpart of one of the longitudinal side of the wall panel. In oneembodiment of the present invention, the stud is positioned so that itsopen slot is exposed on the longitudinal side of the composite wallpanel. In this embodiment, some of the polymeric material is removedfrom the open slot of the stud to form a groove. The other longitudinalside of the composite wall panel is formed with a tongue so that whenthe composite wall panels assembled together, the tongue of one wallpanel will engage the groove of the adjacent wall panel to form acontinuous wall system having planar, non-stepped, exterior surfaces andinterior surfaces.

In another embodiment of the present invention, the light gauge metalstuds are positioned inwardly from the longitudinal sides of thecomposite wall panel so that only one side of each stud is exposed onthe interior surface of the composite wall panel. In a furtherembodiment of the present invention, such wall panel is fabricated witha groove in the panel body along one longitudinal side and a tongue inthe panel body along the opposing longitudinal side so that whenadjacent composite wall panels are assembled together to form a wallsystem, the tongue and groove come together and mate to increase thestrength of the resulting wall system panel and to minimize draftthrough the joint of the adjacent panels and the loss of insulatingvalue for the resulting wall system.

In another embodiment of the present invention, an interior compositewall panel having a single light metal gauge stud with a wall panel bodyof polymer foam. The wall panel has two opposing flat surfaces forminginterior room walls, two parallel and opposing longitudinal sides andtwo parallel end sides, that is, a top and bottom. The stud can beplaced along the edge of a composite wall panel, that is, it canconstitute one of the longitudinal sides or the stud can be positionedwithin the middle of the composite wall panel so that polymer foam formsthe longitudinal sides. The stud extends the full length of the wallpanel and the depth of the wall panel from building wall surfaces is thesame distance as the greatest dimension of the light metal gauge stud.The interior composite wall panel can also be formed with tongue andgrooves as described above.

The composite wall panels of the present invention can be prepared in amold employing conventional light gauge metal studs which can bepurchased off the shelf. Several of the composite wall panels of thepresent invention are prepared from a preformed block of polymer foamand conventional light gauge metal studs as described herein.

Utilities, such as electrical lines, water pipes, sewage pipes, cables,and the like, can be run up from the floor or down from the ceiling of abuilding down through the composite wall panels or they can be passedhorizontally through the wall panels optionally through holes andapertures in the metal studs. The positions of the holes and aperturesin the metal studs can be marked on the exterior major surfaces of thewall panels. However, longitudinal runs of utilities such as wiring andpiping through the studs may require that the foam material be workedout of the central cavity and holes or apertures of the studs in theinterior wall panels and, for that reason, it is easier, quicker, andmore economical to run the utilities from the top or from the bottom ofthe interior wall panel. Runs or channels for the utilities can be cutinto the polymer foam of the panel body using heat guns which arereadily available on the market. Holes, cut or pre-punched, in the lightgauge metal top, or bottom track permit the utilities to be run throughthe tracks into the panel. The runs or channels can be cut in the panelto intercept such holes. Once the utility is placed in the run orchannel, the channel can be back filled with foam from a foam gun or itcan be left open because the surface of the composite wall panel isnormally dressed. The interior surface of the wall panels can be dressedwith gypsum board, or lathe and plaster construction, or with compositepanels, or the like and the exterior surface of the wall panels can bedressed with Tyvek or an equivalent membrane or tar paper and thenstucco, paneling, shingles, brick, masonry, composite paneling,elastomeric coating or the like. Some back filling of the utility run orchannel with polymer foam is desired to prevent freedom of movement ofthe utility in the channel which can create noise, to provide fireblocks and to provide blocks to air drafts.

The studs must be exposed on one of the primary wall surfaces of thewall panel in order to thoroughly fasten gypsum board or other wallcovering to the surface of the composite wall panel and to permit theinstallation of earthquake straps which are required in earthquake pronegeological areas and high wind areas. The composite wall panel cannot beproperly strapped with earthquake straps if the studs are fullyencapsulated by the polymer foam more than a 1/4 inch thick.

A wall system utilizing the composite wall panels is made by securing au-shaped open light gauge metal track to the exterior perimeter of afloor, or the exterior perimeter of a building slab, or a floor system.The panels are dropped into the track positioned side by side and themetal studs of each panel are fastened to the side walls of the trackusing self tapping metal screws. The position of the studs covered bypolymer foam is indicated by a stud marker on the exterior surface sideof the wall panel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a prospective view of the wall system of the present inventionemploying the composite wall panels of the present invention;

FIG. 2 is a bottom view of the composite wall panel shown in FIG. 1;

FIG. 3A is a plan end view of a longitudinal side of the composite wallpanel of FIG. 1;

FIG. 3B is a plan view of the other longitudinal side of the compositewall panel of FIG. 1;

FIG. 4 is a plan view of a primary wall surface of the composite wallpanel of FIG. 1;

FIG. 5 is a plan view of the opposing primary wall surface of thecomposite wall panel of FIG. 1;

FIG. 6 is a prospective view of another embodiment of the wall system ofthe present invention employing another embodiment of the composite wallpanel of the present invention;

FIG. 7 is a bottom plan view of the composite wall panel of FIG. 6;

FIG. 8A is a plan view of a longitudinal side of the composite wallpanel of FIG. 6;

FIG. 8B is a plan view of the other longitudinal side of the compositewall panel of FIG. 6;

FIG. 9 is a plan view of a primary wall surface of the composite wallpanel of FIG. 6;

FIG. 10 is a plan view of the exterior primary wall surface side of thecomposite wall panel of FIG. 6;

FIG. 11 is a top view of another embodiment of the composite wall panelof the present invention;

FIG. 12A is a plan view of a longitudinal side of the composite wallpanel of FIG. 11;

FIG. 12B is a plan view of the other longitudinal side of the compositewall panel of FIG. 11;

FIG. 13 is a plan view of a primary wall surface of the composite wallpanel of FIG. 11;

FIG. 14 is a plan view of the opposing primary wall surface of thecomposite wall panel of FIG. 11;

FIG. 15 is a top view of another embodiment of the composite wall panelof the present invention;

FIG. 16A is a plan view of a longitudinal side of the composite wallpanel of FIG. 15;

FIG. 16B is a plan view of the other longitudinal side of the compositewall panel of FIG. 15;

FIG. 17 is a plan view of a primary wall surface of the composite wallpanel of FIG. 15;

FIG. 18 is a plan view of the opposing primary wall surface of thecomposite wall panel of FIG. 15;

FIG. 19 is a top view of another embodiment of the composite wall panelof the present invention;

FIG. 20A is a plan view of a longitudinal side of the composite wallpanel of FIG. 19;

FIG. 20B is a plan view of the other longitudinal side of the compositewall panel of FIG. 19;

FIG. 21 is a plan view of a primary wall surface of the composite wallpanel of FIG. 19;

FIG. 22 is a plan view of the opposing primary wall surface of thecomposite wall panel of FIG. 19;

FIG. 23 is a top view of another embodiment of the composite wall panelof the present invention;

FIG. 24A is a plan view of a longitudinal side of the composite wallpanel of FIG. 23;

FIG. 24B is a plan view of the other longitudinal side of the compositewall panel of FIG. 23;

FIG. 25 is a plan view of a primary wall surface of the composite wallpanel of FIG. 19;

FIG. 26 is a plan view of the opposing primary wall surface of thecomposite wall panel of FIG. 23;

FIG. 27 is a top view of an interior composite wall panel of the presentinvention;

FIG. 28A is a plan view of a longitudinal side of the composite wallpanel of FIG. 27;

FIG. 28B is a plan view of the other longitudinal side of the compositewall panel of FIG. 27;

FIG. 29 is a plan view of one of the primary wall surfaces of thecomposite wall panel of FIG. 27;

FIG. 30 is a top view of another embodiment of the composite wall panelof the present invention;

FIG. 30A is a partial perspective view of the back side of the lightmetal gauge stud of the panel of FIG. 30.

FIG. 31 is a top view of another embodiment of the composite wall panelof the present invention; and

FIG. 32 is a top view of another embodiment of the composite wall panelof the present invention.

FIG. 33A is a perspective view of a block of polymer foam used in someembodiments of the composite wall panel of the present invention;

FIG. 33B is a perspective view of the channel cut polymer foam block ofFIG. 33A;

FIG. 33BB is an enlarged sectional view of one end of the polymer foamblock of FIG. 33B;

FIG. 33C is a perspective view of the grooved block of polymer foam ofFIG. 33B;

FIG. 33D is a perspective view of the polymer foam block of FIG. 33Creceiving light metal gauge studs to yield the composite wall panel ofFIGS. 35A and 35B;

FIG. 34 is an enlarged fragmentary perspective view of the completedcomposite wall panel of FIG. 33D;

FIG. 35A is a plan view of one primary wall surface of the completedcomposite wall panel of FIG. 33D;

FIG. 35B is a plan view of the opposing primary wall surface of thecompleted composite wall panel of FIG. 33D;

FIG. 36 is an enlarged plan end view of a longitudinal side of thecompleted composite wall panel of FIG. 33D;

FIG. 37 is a plan end view of the other longitudinal side of thecompleted composite wall panel of FIG. 33D;

FIG. 38 is a top view of the completed composite wall panel of FIG. 33D;

FIG. 38A is another top view of the completed composite wall panel ofFIG. 33D;

FIG. 39 is a cross sectional view of the completed composite wall panelof FIG. 33D taken along lines 39--39 of FIG. 35A;

FIG. 40 is a bottom view of the complete composite wall panel of FIG.33D;

FIG. 41 is a fragmentary plan view of an alternative embodiment of thecompleted composite wall panel of FIG. 35A;

FIG. 42 is a fragmentary cross sectional view taken along lines 42--42of FIG. 41;

FIG. 43 is a plan view of a primary wall surface of an alternativeembodiment of the completed composite wall panel of FIG. 33D;

FIG. 44 is an enlarged plan end view of a longitudinal side of thealternative embodiment of the completed composite wall panel of FIG.33D;

FIG. 45 is a plan end view of the other longitudinal side of thealternative embodiment of the completed composite wall panel of FIG.33D;

FIG. 46 is an enlarged top view of the alternative embodiment of thecompleted composite wall panel of FIG. 33D;

FIG. 47 is a cross sectional view taken along lines 47--47 of FIG. 43;

FIG. 48 is a bottom view of the completed composite wall panel of FIG.43;

FIG. 49 is a plan view of another embodiment of the wall system of thepresent invention employing the completed composite wall panels of FIG.33D;

FIG. 50 is a cross sectional view taken along lines 50--50 of FIG. 49;

FIG. 51 is a plan top view showing the assembly of two light metal gaugebottom tracks on a floor system;

FIG. 51A is a fragmentary top view of the completed composite wall panelof FIG. 33D;

FIG. 51B is a fragmentary top view of a modified version of thecompleted composite wall panel of FIG. 51A;

FIG. 51C is a fragmentary top view of a completed composite panel ofFIG. 51A that has been turned upside down;

FIG. 51D is a fragmentary top view of a corner constructed from thecomposite wall panels of FIG. 51B and 51C;

FIG. 52A is a perspective view of a polymer foam block used in someembodiments of the composite wall panels of the present invention;

FIG. 52B is a perspective view of the channel cut polymer foam block ofFIG. 52A;

FIG. 52BB is an enlarged sectional view of one end of the polymer foamblock of FIG. 52B;

FIG. 52C is a perspective view of the block cut polymer foam block ofFIG. 52B;

FIG. 52D is a perspective view of the polymer foam block of FIG. 52Creceiving light metal gauge studs to form an alternative embodiment ofthe composite wall panel of the present invention;

FIG. 53 is a plan view of a primary wall surface of the completedcomposite wall panel of FIG. 52D;

FIG. 54 is a plan view of the other primary wall surface of thecompleted composite wall panel of FIG. 52D;

FIG. 55 is a plan end view of a longitudinal side of the completedcomposite wall panel of FIG. 52D;

FIG. 55A is a plan end view of the other longitudinal side of thecompleted composite wall panel of FIG. 52D;

FIG. 55B is a cross sectional view along lines 55B--55B of FIG. 54;

FIG. 56 is a top view of the completed composite wall panel of FIG. 52D;and

FIG. 56A is a cross sectional view taken along lines 56A--56A of FIG.54.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, the wall system of the present invention comprisesa top track or plate 12A, a bottom track or plate 12B, composite wallpanels 10 and horizontal filler pieces 20. The tongue of the bottom end38B of the composite wall panels 10 are dropped into the open channel 18of the bottom track 12B. The panels are aligned together to form acontinuous wall system 9 having planar exterior and interior surfaces.The composite wall panels are secured to the bottom track by selftapping metal screws 24 which extend through the side walls 14 of thetrack into the side walls 50 of the studs 32. After the composite wallpanels have been assembled together and secured to the bottom track, thetop track 12A is dropped onto the tongues at the top end 38A of thepanels. The top track is secured to the wall panels by screwing the sidewalls 14 into studs 32 with self tapping metal screws 24.

Doors (not shown) for wall structures are made in the usual way withlightweight gauge metal studs and tracks. The transverse width, that isthe width from one longitudinal side 40A of the panel 10 to the otherlongitudinal side 40B (side to side width), can be cut to size with aheat gun down to a size to fit where a door is to be situated.Similarly, windows (not shown) can be constructed in the usual mannerthat they are constructed with light metal gauge studs and track and,optionally, the panel can be cut with a heat gun to accommodate smallerwindows within the space between two studs.

For light gauge metal studs, the "on centers" for the studs is normally24 inches compared to 16 inches for wood studs. A building fabricatedfrom light metal gauge studs and tracks are far stronger than a buildingconstructed from wooden "2×4" frame construction. The gauge of the metalused in the light gauge metal studs can be varied for a particularapplication. Gauges range from 12 to 25, although other gauges areavailable. It is difficult to determine the gauge of a light gauge metalstud when the panels are formed. Accordingly a marker 46 is placed onthe interior or exterior surface, optionally on both surfaces, toidentify the metal gauge. Such a marker is shown in FIG. 1 as element46. The position of the studs on the exterior surface 36 is indicated bymarker 44 which can be a score line, dimples, small depressions, diamondmarks, paint marks or the like. This permits the carpenters andinstallers to determine the position of stud in the panel for purposesof fastening the tracks to the panels and attaching elements, such aswall board, to the studs. Since one of the studs in the composite wallpanel 10 is situated at one of the longitudinal sides of the wall panel,the marker 44 can be omitted for the end stud because carpenters andinstallers know that studs are centered 3/4 inches in from thelongitudinal side of a wall panel. However, wall panels can optionallyhave a marker also showing the end stud. After the wall panels have beenassembled and fastened to the bottom track and top track with fasteners24 as described above, the space partially formed by shoulders 42A and42B is filled with horizontal filler pieces 20. This provides that thesurface 36 of the wall system 9 is flat, smooth and continuous from thetop to bottom and side to side of the joined panels.

Referring to FIGS. 2-5, the composite wall panel 10 has a single piece,continuous polymer foam body 30 and two light gauge metal studs 32partially embedded in the polymer foam body. The studs at least extendfrom one end 38A to the other end 38B of the panel. The studs and lengthof the body 30 can be the same. Shrinkage of the polymer foam during themanufacture of the panels may render the body 30 slightly shorter andnarrower than the studs 32. This slight size difference is notdetrimental to the panel, its use or the wall system fabricated from thepanel. The panels can be manufactured in a mold by injection, extrusion,or the like of the polymer or polymer foam. The polymer foam flows intothe central cavity of the stud through holes 58 in the back wall 52and/or through open slot 56 of the studs 32. It is easier to fill thecentral cavity 57 with polymer foam through the open slot than the holes58 during the manufacturing process. Thus in the preferred embodiment,the open slots of the studs face to the interior of the polymer foambody 30 as shown in panel 10 of FIGS. 1-5 to insure filling the centralcavity of the stud with polymer foam. The filling of the central cavitywith polymer foam strengthens the stud and prevents deflections of thestud side walls 50 during the fastening of the panel studs to the trackswith threaded fasteners or the like. The panels can also be made fromblocks of polymer foam as described below.

The panel can have more than two studs, for example, it can have threestuds on equal centers, such as 16 inch centers for a 48 inch widepanel. The body is a continuous piece of polymer foam and the foamextends into the central cavity 57 of the studs through open slot 56and, in some embodiments, through holes 58 in the stud to securelyfasten the stud and body together. Optionally the stud sides can betreated with an adhesive or primer to aid in cementing the polymer foamto the walls of the stud.

The studs have two narrow side walls 50, a back wall 52 running thewidth of the stud and two small front walls 54 parallel to the back walland separated by slot 56 which is in communication with the centralcavity 57. One of the narrow side walls 50 of the studs 32 is exposed onthe surface 34 of the panel. The body 30 of the panel shields the otherwalls of the studs to prevent corrosion from water and chemicals. Inthis embodiment, one stud, situated on one of the longitudinal sides 40Aof the panel, has one side wall 50 and its back wall 52 also exposed tothe exterior. The light gauge metal studs are normally galvanized coatedsteel optionally painted with a corrosive resistant paint. The back wallof the studs normally have one or more openings 58 which can be used forrunning utility lines and the like through the panel (see FIG. 3B). Thetop of each panel has a shoulder 42A and the bottom of each panel has ashoulder 42B. These shoulders provide large tongues at the top 38A andat the bottom 38B of the panel. The tongues are the width of the studsand fit into the open channels 18 of the top and bottom tracks asdescribed above. One side of each stud is exposed on the interiorsurface 34 of the panel. It is easier to assemble panels with the studsexposed on one primary wall surface, such as primary wall surface 34.However, since the stud is only expose on the one wall surface, thepolymer foam of the body 30 protects the other sides of the studs fromcorrosion as discussed above. A side wall 50 of each studs is exposed.If the studs are positioned on the sides 40A and 40B with the back walls50 facing out, these walls are also exposed. As shown in FIG. 5, theexterior surface bears stud markers 44 to indicate the center of thenarrow wall 50 of each stud so that the installer will know where toattach paneling, lathe board, etc. to the studs of the wall panel withthreaded fasteners (not shown). The exterior surface can also bear atleast one legend 46 indicating the gauge of the light gauge metal stud.Optionally, the legend can appear on the interior surface of the wallpanel or on both surfaces. The legend can be embossed, painted or inkedon the surface of the panel polymer foam.

The body 30 of the panel is one continuous piece of polymer foam. Thefoam as well as the light metal gauge studs are dimensionally stable andare not effected by humidity, dampness or moderate temperature changes.Preferably the polymer foam is preferably closed cell which iswaterproof. Thus the panels can be used in desert, tropical,sub-tropical, arctic and temperate environments and climates.

The panels can be designed for different seismeric zones, wind loads,live loads, dead loads and axial loads prescribed by building codesand/or structural engineers. The polymer foam, especially expandedpolystyrene, has good compressive strength and provides substantialshear resistance and inhibits twisting of the studs.

FIG. 6 shows another embodiment of the wall system of the presentinvention. Common elements between the wall system 9A of FIG. 6 and wallsystem 9 of FIG. 1 bear the same number and the same description as setforth above. The wall system of 9A of FIG. 6 employs another embodimentof the composite wall panel 10A of the present invention. This wallpanel has a longitudinal shoulder 43 running the length of the panelalong one of the longitudinal sides 40 of the panel. When the panels 10Aare assembled together, a slot 26 is created which is filled withvertical filler piece 22 as shown in FIG. 6. In all other respects, thewall system of FIG. 6 is similar to the wall system of FIG. 1.

Referring to FIGS. 7-10, the composite wall panel 10A has a shoulder 43when two panels 10A are abutted against each other with longitudinalside 40A meeting with longitudinal side 40B of the adjacent panel, aslot 26 is created as described above which is filled after assembly ofthe wall system with a vertical filler piece 22 as described above. Inall other respects, panel 10A is similar to panel 10.

The back sides 52 of the light gauge metal studs 32 have rectangular 58Aor holes of other shapes. The polymer foam extends into the holes 58 andopen slot 56 to fill the central cavity 57 of the studs.

Referring to FIG. 11, the composite wall panel 10B has both light gaugemetal studs 32 positioned between the longitudinal side walls 40A and40B of the panel. A stud is not positioned on a side wall 40 as in panel10. In all other respects, the composite wall panel 10B is similar tothe composite wall panel 10A.

Referring to FIG. 15-18, the composite wall panel 10C has a stud 32positioned at one of the longitudinal side walls 40A of the panel withits open channel 56 facing outwardly. In contrast the composite wallpanel of 10 has the open channel 56 of the light gauge metal stud 32positioned on one longitudinal side 40A of the panel facing inwardlyinto the body 30. As in all the composite wall panels, the centralcavity 57 of the studs is filled with polymer foam. The polymer foamextends from body 30C into the central cavity through the holes 58 inthe back wall 52 of the stud to securely bind the body and studs. Thecentral cavity may however, not be completely filled with polymer foam.However, the end stud 32 of panel 10C having its open channel exposed tothe exterior, has a portion of the polymer foam of the central cavity 57cut away to form a groove 49. The other longitudinal side 40B of thepanel 10C is formed with a tongue 48 which is adapted to engage thegroove 49 of an adjacent panel 10C (not shown) when the panels arepositioned and placed and abutted together to form a wall system. Thistongue and groove construction increases the strength of the wall systemsince it helps bind the panels together and inhibits drafts and airleakage through the joint formed by side walls 40A and 40B betweenadjoining panels. In all other respects, panel 10C is similar to panel10.

Referring to FIGS. 19-22, the composite wall panel 10D is similar to thecomposite wall panel 10B with the exception that the panel has a groove49A molded into the body 30D on longitudinal side wall 40A and a tongue48A molded into the body 30D on the other longitudinal side wall 40B.When adjacent panels 10D are abutted or joined together in tracks 12Aand 12B, the groove 49A mates with the tongue 48A of the adjoining panelto form a strong interlocking wall system of the composite wall panels.The tongue and groove construction helps bind the individual panelstogether and inhibits drafts between the joints or seams of adjacentpanels.

Referring to FIGS. 23-26, the composite wall panel 10E is similar to thecomposite wall panel 10 with the exception that the composite wall panel10E is formed with a lip 41 on the primary wall surface 36 of the panelon longitudinal side wall 40A and with a shoulder 43 on the primary wallsurface 36 at the other longitudinal side wall 40B of the panel. The lip41 is designed to engage shoulder 43 of an adjacent panel to form anoverlap joint when the panels are abutted and joined next to each otherin light metal gauge tracks 12A and 12B. The overlap joint preventsdrafts between the joint or seam of adjacent panels. Some studs 32available on the market have round holds, rectangular holes 58 squareholes or other shaped holes in their back walls 52. In all otherrespects, the composite wall panel 10E is similar to the composite wallpanel 10.

Referring to FIG. 27, a wall composite wall panel 70 is shown which isnormally half the transverse width of the composite wall panels 10Athrough 10E. It is envisaged that panel 70 will be used primarily ininterior wall systems. However, it can be used in the exterior wallsystems. Preferably the composite wall panels 10-10E are used forexterior walls. Conveniently, the transverse width of panel 70 betweenthe longitudinal side walls 74A and 74B is a standard buildingconstruction distance between the studs, center to center, required forthe wall structure. Typically, this is 24" or 16". Interior compositewall panel 70 comprises a body 72 of polymer foam and a light gaugemetal stud 32 secured at one end of the body. The polymer foam extendsinto the central cavity 57 of the stud. The width of the panel betweenthe primary wall surfaces 76A and 76B is the width of the stud 32. Theinterior composite wall panel 70 is thinner than composite wall 10-10Epanels because the insulation demands of interior walls is much lessthan exterior walls. The panels 70 are utilized and assembled in thesame manner as panels 10-10E.

Referring to FIGS. 28A, 28B and 29, a bottom track 12B is attached to aflooring system 17. The bottom sides of 78B of one or more panels 70 areinserted into the open channels 18. The lower track 12B and upper track12A are shown in phantom in FIG. 29. A plurality of panels are insertedinto the track and abutted up against each other to form a continuous,smooth interior wall (not shown). In this manner, studs 32 of each panelwill be "on center" as required by the building codes. After the panelsare assembled in the bottom track, the top track 12A is lowered onto theupper side 78A of the panels 70 with the open channel extending over andonto the upper side 78A. Side walls 14 of the upper track and lowertrack keep the walls aligned to form a smooth continuous wall surface oneach side of the panels. The panels are screwed into the tracks byscrewing in self tapping meal screws 24 through the side wall 14 of thetracks into the side walls 50 of the studs 32 of the panel. The panelsurfaces 76A and 76B can be plastered, covered with sheet rock, tiled orthe like. The sheet rock or other paneling can be adhesively attached tothe panels or screwed into the studs of the panels.

Doors and other elements in walls can be made with light metal gaugestuds and light metal gauge track in the conventional manner. Utilitiesare brought down from above or up from below through holes in the tracksand runs or channels in the polymer foam of the body cut with heatknives. Alternatively, the utilities can be run horizontally through thepanels.

Referring to FIG. 30, an alternative embodiment of the interiorcomposite wall panel 70A has the light metal gauge stud 32 positioned inthe body 72A of the panel between the longitudinal walls 74A and 74B.The body 72A of the panel extends on both sides of the stud and thepolymer foam of the body extends into the central cavity 57 of the stud.The back wall of stud 52 has a plurality of apertures 58 (see FIG. 30A)which can be circular, rectangular, square, diamond shaped, oval shaped.The polymer foam extends into the central cavity through the open slot56 and through the holes 58 to securely bind the stud with the polymerfoam body.

Referring to FIG. 31, another embodiment of the interior composite wallpanel 70B comprises a body 72B and a stud 32. The body 72B is composedof polymer foam as the other composite wall panels of the presentinvention and the polymer foam extends through the apertures 58 (notshown) in the back wall 52 of the stud 32 into the central cavity 57 ofthe stud. The polymer foam extending through the aperture 58 between thecentral cavity and the body 72 binds the stud 32 securely with the body.

Referring to FIG. 32 a composite wall panel 80 having a large, i.e.,wide stud 32A and a thick body 30F is shown. Such large dimensionalpanels can be easily made and used. Such panels would find use for heavyconstruction were the ceiling, upper floor or roof loading would besubstantially greater than found in typical 1-3 story framed buildings.The polymer foam fills the body 30F and extends into the central cavity57A of the stud through open slot 56A.

Referring to FIG. 33A, in an alternative embodiment of the presentinvention, the panels can be made from a pre-formed rectangular block ofpolymer foam having the outer dimensions equivalent to a standard wallpanel, such as a panel 4'×8' and 51/2" to 6" thick. Preferably the panelwidth is 1/16" to 1/18" narrower than a standard width, such as 4' widthto give a certain amount of play when assembling a wall system. Theblock of polymer foam is channel cut with a conventional device such ashot wires or hot knives to form c-shaped channels 102 running the lengthof the polymer foam block 100 which are adapted to receive light metalgauge studs described above to form polymer foam block 100A. The polymerfoam block 100A is grooved with a hot knife or a hot wire to form alateral groove 104 cut into the top end 106 and bottom end 108 of theblock. The groove 104 and the bottom primary wall surface 112 of thepolymer block form a tongue 121 which is adapted to be received in theopen channel 18 of a track 12 similar in fashion to the other compositewall panels described herein. The top primary wall surface 110 of thepanel is partially grooved with a hot knife or a hot wire to formlateral partial grooves 114A and 114B on the primary wall surface 110 atthe longitudinal ends of the block, partial length longitudinal partialgrooves 116 on the primary wall surface 110 of the polymer foam block atthe longitudinal ends, a full length longitudinal partial groove 118 onsurface 110 along one side of the polymer foam block and partial groovesfor an access slot 120. The partial grooves only extend a short distanceinto the surface of the polymer foam block, such as 1/8" to 1/2". Thesegrooves are guidelines for a construction worker to cut along when it isnecessary to remove a foam piece as described herein. A deep groove iscut along the end of each block 100C to the depth longitudinallyco-extensive with lateral partial groove 114A. A full lengthlongitudinal deep groove 122 is cut into the side 124 of the polymerfoam block 100C which extends laterally into the foam co-extensive withthe full length longitudinal partial groove 118. Thus, when the polymerfoam is cut along groove 118 to the depth of the deep groove 122 (seeFIG. 35B) along the full length of longitudinal partial groove 118, thelongitudinal strip of polymer foam 132 is released (see FIGS. 46-48 and51B). When the polymer foam is cut along grooves 114A or 114B and 116 tothe depth of the deep groove 123, a strip of polymer foam is released(see FIGS. 41, 42, 49 and 50).

Referring back to FIG. 33, light metal gauge studs 32 are inserted intothe c-shaped grooves 102 and pushed along the longitudinal length of thepolymer foam block. The c-shaped channel extends the full length of theblock. The studs are the same length as the polymer foam block andextend from one end 106 to the other end 108.

Referring to FIG. 34, the top portion of the completed composite wallpanel 100D is shown showing the studs 32 fully inserted into the polymerfoam body 100C, and showing how the lateral partial grooves 114A and114B, the partial length longitudinal partial groove 116 and the fulllength longitudinal partial groove 118 only extend a short distance intothe surface 110 of the polymer foam. The partial grooves for the accessslots 120 extend deeper into the polymer foam. This permits the workmento easily remove the access slots in order to fasten a bottom track ortop track to the studs 32 of the completed composite wall panel whenthey are installed into the tracks. The lateral groove 104 is wider thanthe other grooves in order to permit one side wall 14 of the track toeasily be inserted into groove 104 as tongue 121 is dropped into theopen channel of a track.

Referring to FIGS. 35A, 35B, 36, 37, 38, 38A, 39 and 40, the completedcomposite wall panel 100 of FIG. 33D is illustrated. The primary surfacewall 110 of the composite wall panel 100D bears the partial grooves114A, 114B, 116, and 118 described above. In its unaltered state, thestuds 32 of composite wall panel do not show on primary wall surface110. The other primary wall surface 112 of the panel shown in FIG. 35Bhas the studs 32 positioned on the surface of the primary wall surface112. The depths of deep grooves 104, 122 and 123 are shown in phantom inFIG. 35B. It can be seen in the top view, bottom view and crosssectional views of FIGS. 38-40, the studs 32 only extend about 2/3 ofthe way through the thickness of the polymer foam block. Thus the wallsof the studs cannot be seen on the primary wall surface. Primary wallsurface 110 is normally the interior wall surface because it permitseasier installation of utilities that will be described herein. Primarysurface 112 is the surface normally facing the exterior and thevisibility of the studs gives the construction worker guidance insecuring the wall surface, whatever it is, paneling, lathe, wire forstucco, and the like, to the studs.

The lateral groove 104 is wide enough to receive the side wall 14 of atrack 12 (the channel tracks are illustrated in FIGS. 1, FIGS. 6 and thelike above and as shown at the bottom of FIG. 36 with the track shown inphantom). The groove 104 only extends a short distance into the ends ofthe composite wall panel, just far enough to easily receive the sidewall 14 of a track (see FIG. 35B).

The full length longitudinal deep groove 122 extends the full length ofthe composite wall panel and extends inwardly from the side 124 of thewall panel as far as the full length longitudinal partial groove 118 ascan be seen in FIGS. 35B and 39. When the full length partial groove 118is cut with a hot wire or knife down to the deep groove 122, a strip ofpolymer foam 132 is freed from the composite wall panel.

Referring to FIGS. 41 and 42, the composite wall panel 100D has had aportion of the primary wall surface 110 removed in area 134 by havingpolymer foam cut with a knife or with a hot wire or hot knife alongpartial length longitudinal partial grooves 116 and partially along thelateral partial groove 114A down to a depth of deep groove 123. Thepanel is dropped into and mounted on a track 12B (shown in phantom). Theside wall 14 of the track is secured to the side wall of stud 32 with afastener 24 (shown in phantom). Normally, this type of cut would not bemade in the panel for purposes of securing the panel to a track. Tosecure the panel to the track, the partial grooves for access slots 120are cut down to the depth of the lateral deep grooves 123 to remove thefoam and expose the side wall of the track (see FIG. 40 which shows theaccess slot and FIG. 41 which shows the access slot removed and afastener 24 positioned to secure the side wall of the track to stud 32).FIG. 42 shows the stud 32 fitted into track 12 and secured withfasteners 24 the (track is shown in phantom). As shown in FIG. 42, aportion of the polymer foam has been cut away along the original grooveline 114A down to the deep lateral groove 123 to form open area 134.

Referring to FIGS. 49 and 50, an alternate embodiment of the wall systemof the present invention is illustrated employing the composite wallpanels 100D. Composite wall panels 110D have been modified by cuttingalong the length of the lateral partial groove 114A at the bottom 108 ofthe composite wall panel down to the deep lateral groove 123 to exposethe side wall 50 of the studs 32. This cut frees a strip of polymer foamfrom the panel. The longitudinal depth of deep lateral groove is shownin phantom in FIG. 35B. The strip of polymer foam can be removed beforethe composite wall panel is assembled into the bottom track 12B or afterit is actually fastened and secured into track 12B. In either case,after the composite wall panel is fitted into the bottom track 12B, thespace occupied by the polymer foam strip cut out along the groove line114B and the lateral deep groove 123 is replaced with an anchor base 130normally made of wood, such as a 2×4 or the like. The anchor base issecured to the bottom track 12B by long self-tapping threaded fasteners,such as 21/2" fasteners. The fastener extends through the side wall 14and side wall 50 of the stud and secures the side wall 14 of the bottomtrack 12B to the side wall 50 of the stud 32. An anchor base can also beinstalled at the top 106 of the wall panel 100D in a similar fashion tothe anchor base illustrated in FIGS. 49 and 50. The anchor base at thebottom of the panel can be used as a base to install molding, securecabinets, bookshelves, and the like. The wooden anchor base provides aconvenient medium to nail or screw the molding to. Similarly, an anchorbase at the top of the panel can be used to secure ceiling molding,crown molding, or hanging cabinets or the like.

The wall system is anchored at the top with the top track 12A which isfitted over the tongue 121 of wall panels with one side wall 14 insertedinto the groove 104 of the composite wall panel and the other side walladjacent the primary wall surface 112. The top track 12A is secured tothe composite wall panel by fasteners 24 as described above.

Referring to FIGS. 43, 44, 45, 46, 47 and 48, modification is shown tothe composite wall panel 100D which is made by construction workers toprepare wall panels for the creation of a corner. The constructionworker cuts along the entire length of the longitudinal partial groove118 down to the full length longitudinal deep groove 122 to free a stripof polymer foam 132 (see FIG. 33D) leaving along the length of thecomposite wall panel exposing one side wall 50 of the end stud 32 of thecomposite wall panel. In all other respects, the composite wall panel100E is identical to composite wall panel 100D.

A corner can be easily assembled for the construction of a buildingemploying the composite wall panels 110D in combination with compositewall panels 100E, using one of each for each corner.

Referring to FIG. 51, bottom track 12B' is secured to the floor withfasteners 140. Track 12B" is then butted up against the end of track12B' at right angles to form the corner as shown. Now referring to FIGS.51A through 51D, composite wall panel 100E is prepared from compositewall panel 100D as described above to remove the polymer foam strip 132as shown in FIG. 51B. Composite wall panel 100E is fitted into bottomtrack 12B' with the side 124 of the composite wall panel 100E contiguouswith the end 142 of the bottom track 12B'. Composite wall panel 100D isthen dropped into bottom track 12B" and the end 124 of the compositewall panel is butted up against the exposed grooved surface of the fulllength longitudinal deep groove 122. Composite wall panel 100E issecured to composite wall panel 100D by fastening the end studs of bothwall panels as shown in FIG. 51D with a long, such as 41/2", threaded,self-tapping fastener 24B.

Referring to FIGS. 52A through 52D, an alternative embodiment of thecomposite wall panel of the present invention is shown. A polymer foamblock 100 is grooved with a knife, hot knife or hot wire to formc-channels 102 which extend along the full length of the block. Tonguesare formed at each end of the polymer foam block 100A by removinglateral strips 150 with a knife, hot knife or hot wire to yield apolymer foam block 100G. Studs 32 are inserted into the c-shapedchannels 102 which are adapted to receive the light metal gauge studs.The studs are the same length as the polymer foam block and extend thefull length thereof after the light metal gauge studs are inserted intothe polymer foam block. The resulting composite wall panel is similar tocomposite wall panel 10A described above.

Referring to FIGS. 53, 54, 55, 55A, 55B, 56 and 56A, the composite panel10A is prepare from a single pre-formed polymer foam block 100substantially identical to the composite wall panel 10A illustrated inFIGS. 7, 8A, 8D, 9 and 10 above. The same numbers are used for the sameelements.

FIG. 53 shows the composite wall panel mounted in a lower track 12B andsecured at the top by upper track 12A. The side walls of track 14 aresecured to the studs 32 of the composite wall panel with fasteners 24 asdescribed above. The adjoining wall panels are not shown. With a hotwire tool, utility ducts 202, 204 and 206 have been cut into the innersurface 34 of the panel using a hot knife, a receptacle well 200 hasbeen cut into the surface 34 to receive an electrical box or the like.

The panels can be utilized in either direction. That is, the wallsurface 34 can be positioned to the outside of a building or towards theinside of a building. Normally, it is positioned towards the inside of abuilding since it provides about 2" of foam between the inner side ofthe studs 32 and the wall surface 34 which can be easily cut with a hotwire, knife or device to form utility channels for plumbing, wiring,cabling, gas lines, and the like.

The composite wall panels of the present invention offer many advantagesover the existing metal/polymer composite wall panels. The compositewall panels are made from commercially available materials including thelight metal gauge studs 32 and the polymer foam. Many types of polymerfoams can be utilized including extruded polymer foams such aspolystyrene, polyethylene, polyisocynaurite and polyurethane andexpanded polymer foams such as polystyrene and polyurethane. The panelsare dimensionally stable and have flat continuous surfaces to provide acontinuous smooth wall system having flat planar surfaces which can beeasily covered with lathe and plaster, gypsum board, composite panels,tile and the like. The panels are lightweight and can be easily carriedby a single man or woman even when they contain up to four studs andhave dimensions as great as 4×12'. The composite wall panels will notsupport combustion. The polymer foam incorporates a fire resistantmaterial known to the art such as halogenated phosphates, antimonyoxide, and the like. The polymer foam is preferably a closed cell foamwhich prevents water saturation and offers a greater degree of thermaland sound insulation. The panels are completely impervious to dry rotand completely resistant to termite damage. The passive interaction ofthe studs with the polymer foam body, and the passive interaction of theassembled panels in a wall system secured with the top track and bottomtrack, provide an extremely strong and rigid wall which offerstremendous lateral stiffening and far greater vertical load bearingcapacity than comparable wood framing walls.

An additional advantage of the composite wall panels arises because theydo not have to undergo extensive testing to obtain building andstructural approvals from governmental agencies, ICBO, BOCCA, and thelike, because light gauge steel construction is already accepted andwidely used in the building industry.

The panels can be used to build a structure employing standard woodframing techniques. The wall/frame assembly using the panels can becarried out on the ground or on the floor and then the wall/frameassembly is raised as a complete wall system with detailing completedwhen the wall is up, such as plumb and line of the walls and completingthe fastening of the tracks and studs.

The panels are squared and have straight flat walls. Thus the panels andtracks are assembled with a minimum of plumbing compared to straightwood or light metal framing. Yet the assembled wall system retainssufficient give to permit slight racking of the assembly to make theassembled wall system plumb when the floor system is not exactly level.

In conventional light metal framing, the studs side walls 50 must beclamped to the track side walls prior to fastening because when thefasteners are screwed through the side wall 14 of the track 12 into theside wall 50 of the stud 32, the side wall of the stud can bend inwardlytoward the open slot 56 of the stud causing a gap to form between theside wall of the track and the side wall of the stud. This gap weakensthe joinder of the stud and track, and, thus, the stud side wall isclamped to the side wall of the track to prevent such gaps. This gapproblem is advoided with use of the present panels because the polymerfoam, which at least partially fills the central cavity 57 of the stud,prevents a side wall of the stud from flexing inwardly toward the openslot 56. Thus the tracks and panel studs can be fastened without theneed for clamping.

The composite wall panels can be manufactured in molds to form acontinuous body of polymer foam. Studs can easily be positioned in themold with one side wall 50 of the studs 32 positioned at the bottom ofthe mold in register with the interior surface of the wall panel. Thepolymer foam can be injected, molded or extruded into the moldcontaining the studs to form the composite wall panels described herein,or the polymer foam can be formed into blocks which are cut to receivethe studs.

Conventional light metal gauge studs, also known as light gauge steelstuds, light weight, cold-formed steel members, cold-formed steelstructural members, metal studs or steel studs, c-stud, joist, can beemployed in the present invention including SHD, X SHD and XX SHD studshaving various leg sizes such as 13/8 inch, 11/2 inch, 2 inch andvarious web sizes, such as 31/2 inch up to 8 inch. The web size is thewidth of the stud and the leg size is the thickness of the stud. Thewidth of the back wall is equivalent to the web of the stud and thelength of the side wall is the length of the leg of a stud. The lightmetal gauge studs employed in this invention preferably are engineeredto meet the specifications of the 1986 Edition of the AISI (AmericanIron and Steel Institute) publication "Specification for the Design ofCold-Formed Steel Structural Members", including 1989 amendments andcomply with the Uniform Building Code.

We claim:
 1. A structural, insulating, insect resistant, dimensionallystable composite wall panel for building construction comprising aregular tetragonal body of polymer foam having two opposing primary wallsurfaces bounded on its sides by two parallel side walls and on its endsby two parallel end walls; and at least two light metal gauge studs inthe body, each stud having a hollow center cavity, a squared crosssection with a wide back wall extending the width of the stud, twoparallel side walls, two narrow front walls separated by a open slotextending into the central cavity, each light metal gauge stud at leastextending from one end wall to the other end wall and parallel to theside walls of said body, the polymer foam extending into the centralcavity of the studs to secure the studs to the body, the width of thepanel between the primary wall surfaces being greater than the width ofthe studs, at least one side wall of each stud forming a portion of thesame primary wall surface of said body, the back wall of one stud beinga part of one of the side walls of said body, said body having a tongueportion at each of its ends, the tongue portion having a width equal tothe width of the studs, the tongue portion adapted to be received by andsecured in the open channel of light metal gauge building constructiontrack to form a structural wall.
 2. The composite wall panel accordingto claim 1 wherein the width of the wall panel between its sides isequal to a standard building construction center to center distance forstuds or a multiple integral multiple thereof.
 3. The composite wallpanel according to claim 1 wherein the distance between the studs, fromcenter to center of the studs is a standard building construction centerto center distance for studs.
 4. A structural, insulating,insect-resistant, dimensionally stable composite wall panel for buildingconstruction comprising:a rectangular, tetragonal body of polymer foamhaving two opposing primary wall surfaces bounded on its side by twoparallel side walls and on its ends by two parallel end walls; two lightmetal gauge studs in the body, each stud having a hollow central cavity,a squared cross-section with a wide back wall extending the width of thestuds, two parallel side walls, two narrow front walls parallel to theback wall and separated by an open slot extending into the centralcavity, each light metal gauge stud extending at least from one end wallto the other end wall of the polymer foam body and parallel to the sidewalls of said body, the polymer foam extending into the central cavityof the stud to secure the stud to the body, at least one side wall ofeach stud forming a portion of the same primary wall surface of saidbody, the distance between the studs, center to center of the studs,being a standard building construction center-to-center distance forstuds, at least one stud forming a portion of one of the side walls ofsaid polymer foam body, the width of the polymer foam body between theprimary wall surfaces being greater than the width of the studs, saidpolymer foam body having a tongue portion at each of its parallel endwalls, the tongue portion having a width equal to the width of the studsand adapted to be received by and secured in the open channel of lightmetal gauge building construction track to form a structural wall.